Process for manufacturing multi-ply labels

ABSTRACT

An in-line, single pass, multi- or single-web process for producing resealable multi-ply labels is disclosed which includes automation of an inclusion of intermediate label plies having dimensions different from final individual label dimensions.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates generally to the field of labeling and, inparticular, the present invention provides a continuous in-line processfor constructing multi-ply resealable labels that accommodatesintermediate plies smaller in size than the overall label dimensions.

II. Related Art

Multi-ply labels, variously referred to as “multi-layered”, “extendedtext”, “expanded content” or “booklet” labels, carry text on a pluralityof surfaces and are useful for consumer products, particularly thosesold in bottles, cans, cartons, and tubes, where it is desirable topresent additional information to the consumer which cannot convenientlybe contained on a single printed label surface. Particularly in view ofthe increasing amount of governmental regulation and labelingrequirements, many consumer products contained in such packaging mustcarry additional information including detailed instructions for use,detailed listings of the contents, a variety of consumer productwarnings, and provisions for multi-lingual information.

Multi-ply labels normally contain two or more layers or plies of labelmaterial hinged together adhesively along one margin, and closeutilizing a pressure sensitive release-reseal system along the oppositemargin. It is often desirable that one or more internal, middle orintermediate plies be added between an upper or top ply and a bottom orbase ply. It is further advantageous if the intermediate plies can behinged between the top ply and base plies yet not interfere with or berequired to be part of a release-reseal closure system involving top andbase plies. This can be accomplished by making internal or intermediateplies shorter than the top and base plies so that the free ends of theintermediate plies do not extend into the release-reseal margin area. Inthis way, intermediate plies are hinged like the pages of a book when alabel is open, yet are confined within a resealed or closed label.

While the above is a desirable configuration or label construction forlabels of a class having three or more plies, automation of an in-line,single pass process to mass produce such labels has been thwarted. Oneproblem arises because the slightly smaller intermediate ply or pliesmust be sized separately and prior to any final sizing cut for theassembled labels. This problem, among others, has heretofore proved tobe an impediment to mass production in-line, single pass automation.

One in-line process for multi-ply labels is illustrated and described inU.S. Patent Application Publication US 2002/0084026 A1 to Matthews etal., teaching the use of a pressure-sensitive adhesive overlaminate tohold two webs together. That in-line construction, however, results in acostly and unnecessarily complex multiple layer label.

Thus, it would present a distinct advantage if the process for makinghinged multi-ply labels could be simplified and automated, particularlyfor those multi-ply labels designed to have one or more under-sizedintermediate plies configured in resealable booklet-label form.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a processfor manufacturing resealable multi-ply labels that includes a first orbase ply having an under side and an upper side and typically an amountof a pressure sensitive adhesive (PSA) material (defined below) on theunder side to attach the label to an object, normally a container ofinterest to be labeled. A top ply is provided having-an upper side andan under side and the upper side of the base ply and the under side ofthe top ply are designed to be joined together permanently along a firstor hinge edge or hinge strip, preferably by an amount of a permanentadhesive (PA) material (defined below), which is not pressure sensitiveand which thereby forms a permanent hinge. Of course, in someapplications, hinges may be conveniently formed using a pressuresensitive adhesive material (PSA) (also defined below).

As will become apparent, an important aspect of the process of theinvention involves in-line, single pass inclusion of additional middleor intermediate plies which are attached between the top ply and thebase ply. Intermediate plies may be attached using (i) a portion of thehinge strip fastening the base ply to the top ply, or (ii) usingmultiple hinges, one provided between each of the layers or plies insandwich fashion.

The upper side of the base ply and the under side of the top ply arealso releasably, resealably, joined along an opposite or second edge oralong an outer release-reseal margin opposite the hinge or at one ormore release-reseal strips spaced from a central hinge strip (dependingon the label configuration). A dual layer release-reseal system is usedwhich includes a layer of pressure sensitive adhesive material and anabutting layer (top/bottom) of a release coating such that the plies canbe separated and resealed at a juncture therebetween.

The present invention relates to the in-line, single pass manufacture ofsuch labels, particularly those having middle or intermediate plies.More particularly, the present invention relates to such manufacturingof labels having one or more intermediate plies that are of a sizedifferent from that of the base and top plies or the overall label size.Most notably, the present invention accomplishes simplified in-line,single pass manufacture of multi-ply labels in which one or moreundersized (shorter) intermediate plies are included within a bookletlabel. The labels are preferably processed continuously using multi-unit(modular) in-line narrow or wide web printing and converting platformpresses selectively capable of providing a variable number of printingand converting stations. This includes stations for the application anddrying of pigmented inks, coatings and adhesives of different types andstations accomplishing converting processes such as unwinding, turning,die cutting, joining and re-winding.

The manufacturing process may be carried out by using multiplecontinuous webs, i.e., one web per ply, using a single continuous web,or some combination thereof. In any event, the process enables thecontinuous production of multi-ply labels having intermediate or middleplies of smaller size, particularly shorter than those of the top andbase plies. This is accomplished in one preferred embodiment byproviding a web die cutting step prior to a web joining or ply assemblystep in the case of a multi-web system, in which, more importantly, thedie cutting step is one that does not disturb web integrity. In anotherpreferred process embodiment, a “window”-creating die cutting step isprovided in a single web label generating system which removes a portionor “window” of unwanted material from intermediate plies to accomplishsize reduction.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings wherein like numerals are utilized to designate likeparts throughout the same:

FIG. 1 is a cross-sectional view of an embodiment of a multi-ply labelincluding an intermediate or middle ply suitable for manufacture by theprocess of the present invention;

FIG. 2 depicts an alternative construction for the embodiment of FIG. 1utilizing consecutive or stacked hinges in a sandwich-type arrangement;

FIG. 3 is a schematic diagram of one preferred method of manufacturinglabels according to the present invention;

FIG. 4a is an illustration of a fragment of an intermediate ply-carryingweb from the process of FIG. 3 greatly enlarged;

FIG. 4b is a cross-sectional view of the label web of FIG. 4a takenalong line B—B;

FIG. 5 is a schematic diagram of an alternate preferred method ofmanufacturing labels according to the present invention using a singleweb; and

FIG. 6 is an illustration of progressive views of an enlarged fragmentof an exemplary web of labels created in accordance with themanufacturing method of the present invention.

DETAILED DESCRIPTION

In regard to the construction of the labels in accordance with theprocess of the present invention, certain criteria regarding theconstruction of the labels will be described. Those skilled in the artwill also recognize that the processes described herein are presented asexamples and are not intended to be limiting with regard to the scope ofthe invention in any way.

As has been indicated, in the construction of the labels using theprocess of the invention, two distinct categories or types of adhesivematerials may be employed in the labels, namely, “permanent” adhesive(PA) materials and “pressure-sensitive” adhesive (PSA) materials. It isto be particularly appreciated that, as used herein, a “permanent”adhesive is one that is a tack-free solid in the cured or final adhesivestate, in bonding plies together. The class known as “permanent”adhesives may be further defined by a universally accepted referencetext, The Concise Encyclopedia of Polymer Science and Engineering (NewYork, 1990.), which states, at page 35, with respect to permanentadhesives, the distinguishing feature that “Eventually, the adhesivemust undergo a phase change, i.e., by cooling, solvent evaporation orreaction, to a solid in order for the joint to acquire the necessarystrength to resist shearing forces.”

Examples include hot melt adhesives, solvent-based adhesives,water-based adhesives, and UV- (ultraviolet) and EB- (electron beam)curable adhesives.

The class of adhesives known as “pressure-sensitive” adhesives (PSA) iscontrasted as an exception to the above in the next sentence of theabove-mentioned reference publication which reads, “A notable exceptionis the category of pressure-sensitive adhesives, where no phase changeoccurs.” This also describes the term “pressure sensitive” as usedherein. These materials remain tacky. Adhesion may be modified (reduced)by detackifying overlayers but the material does not solidify.

The in-line, single pass process variously embodied in the presentinvention, however, will operate successfully with either type ofadhesive desired and does not limit label construction from thatstandpoint. Within a class, preference of one such adhesive over anotherparticularly will depend upon a drying or curing system of a given labelmanufacturing press, along with materials composition and compatibilityconsiderations. In addition, in a dual layer release-reseal system,coatings abutting in the assembled label may be applied to thecorresponding plies in either order, either separately, one on each plyor together as a combination on one of the plies. Thus, for example, thepressure sensitive adhesive may be applied to the upper side of the baseply or to the under side of the top ply and the release coating may beapplied on the whole of the opposite facing surface exclusive of thehinge area or a lesser area down to just as much of that surface as iscovered by the pressure sensitive adhesive. The pressure sensitiveadhesive also may be applied in an intermittent pattern along theopposite edge and also along the remaining opposed side edges, or in anyother pattern if desired.

The release coating may be a varnish, lacquer, or any other coatingwhich accomplishes the effect of a release medium and allows thepressure sensitive adhesive to adhere to the ply only lightly so that itmay be peeled back or released and resealed. Additional plies may beadded as required.

FIGS. 1 and 2 show side or cross-sectional views of a resealable,multi-ply label 10 having a first or base ply 12 having an upper side 14and an under side 16. Label 10 includes a top ply 18 having an underside 20 and an upper side 22.

The top ply 18 is joined to the first or base ply 12 along a strip thatis normally a hinge margin or edge 23 preferably using a permanentadhesive material 24 to form a binding or hinge. The adhesive material24 is designed to cause permanent adhesion so that the top ply 18resists unintentional peeling away and removal from label 10. Pressuresensitive adhesives may also be used in the hinged construction of suchmulti-ply labels in accordance with the process of the presentinvention.

A middle or intermediate ply 30 is shown between base ply 12 and top ply18. Ply 30 is also hinged by the hinge adhesive material 24 along oneedge at 32 and has free sides and a free end 34. End 34 terminatesbefore reaching the pressure sensitive adhesive 28 of the release-resealsystem so that it is “captured” within the label 10 when the top ply 18is held closed by the release-reseal system.

The plies 12, 18 and 30 may be made of any suitable material that meetsthe physical and chemical compatibility requirements, along with desiredaesthetic attributes and cost considerations, of a particular label. Itis to be understood that where necessary, surfaces of the plies to beprinted may receive one or more additional depositions of material toadjust the receptiveness to printing materials. Thus, an array ofpapers, plastics, and related materials may variously be employed forthe plies, the surfaces of which may be adjusted as needed by thoseskilled in the art.

As seen in FIGS. 1 and 2, a portion of the upper side 14 of the base ply12 is provided with a layer of release coating 26 which may cover theentire area of the upper side 14 exclusive of regions having hingeadhesive coating 24 in “zone coat fashion” or some lesser amount asshown in FIGS. 1 and 2. As used herein, “layer” is intended to includeany coating applied by a suitable deposition technique. The layer ofrelease coating 26 is typically a varnish, lacquer, ink, or othercoating that inhibits adhesions. A layer of pressure sensitive adhesiveis shown at 28 which, in conjunction with the release coating 26 enablesrelease and resealing of the upper ply 18, and may be characterized, incombination, as a “release-reseal system”. A pattern of the pressuresensitive adhesive material in the release-reseal system may be in theform of a continuous, or a discontinuous or intermittent pattern, itonly being necessary that the pattern of the pressure sensitive adhesivebe substantially aligned with the release coating when the plies aresealed and that it provide sufficient tack to prevent unaided orunintentional opening of the label as may occur, for example, in aproduct labeling assembly line or on a retail shelf.

In the embodiment of FIG. 2, base ply 12 is joined to intermediate ormiddle ply 30, as is middle ply 30 to top ply 18 along a strip that is ahinge margin or edge using adhesive material 24 to form a binding, i.e.,a stacked or consecutive pair of full hinges at 32.

Permanent adhesive material 24 is preferred to create permanent hingesso that intermediate ply 30 resists unintentional peeling away andremoval from label 10. Top ply 18 is permanently hinged by hingeadhesive material 24 to middle ply 30. It can be seen, therefore, thatthis construction comprises an overall “adhesive sandwich” ofalternating plies and adhesive materials at the hinge margin or hingeedge. It is to be particularly appreciated that such a construction, ifdone utilizing pressure-sensitive adhesive hinge materials, almostwithout exception, will result in “adhesive ooze” and many problemsattendant therewith in dispensing, application, and use of label 10.

As described relative to the embodiment of FIG. 1, intermediate ply 30in FIG. 2 also has free sides and a free end 34, which terminates shortof the pressure-sensitive adhesive of the release-reseal system as wasthe case with the embodiment of FIG. 1. The combination of a layer ofpressure-sensitive adhesive material 28 and a layer of release coating26 (in any order) forms a “release-reseal system” between plies 12 and18. As illustrated, a portion of upper side 14 of base ply 12 isprovided with a layer of release coating 26 which may cover an entirearea of upper side 14, exclusive of regions having hinge adhesivematerial 24, or some lesser amount.

As can be seen in the figures, the release-reseal system may bepreferably limited to a strip in the vicinity of a second edge as at 36which is opposite the hinge margin or hinge edge or strip 23. Of course,the release-reseal system requires only that the release coating 26 besubstantially aligned with the pressure sensitive adhesive 28 on theopposed surface of the adjacent ply.

Any of the labels may be provided, if desired, with an additional layerof adhesive 29 on the under side of the base ply 12, to attach the labelto an object of interest to be labeled such as, for example, a bottle ofa medicinal preparation or other health or beauty aid product. The labelmay be conveniently stored, delivered, and dispensed from a releaseliner (not shown) to protect the attachment surface.

Directing attention now to FIG. 3, there is depicted in schematicfashion an example of an in-line or modular web press manufacturinginstallation, generally 300, including multi-unit in-line printing andconverting press 310, for mass or continuous production of, for example,the aforedescribed labels of FIGS. 1-2. As seen in the Figure, theconverting press 310 as depicted is configured to process three webs320U, 320I and 320B respectively, which carry the top, intermediate (ormiddle), and base plies of a label of interest.

Multi-unit press 310 of installation 300 includes (i) unwind units 330a, 330 b, and 330 c, (ii) first printing units 340 a, 340 b, and 340 c,(iii) web turning units 350 b and 350 c, (iv) second printing units 360a, 360 b, and 360 c, (v) release-reseal system unit 362, (vi) first diecutting unit 364, (vii) first nip roller web joining unit 370, (viii)waste matrix removal unit 372, (ix) downstream printing unit 374, (x)second nip roller web joining unit 380, (xi) second die cutting andwaste matrix removal unit 382, and (xii) final re-wind unit 390, as willnow each be further described in construction of, for example, a web oflabels as shown in FIG. 6.

It is to be understood that press 310 may take many forms and may bemade selectively capable of providing a variable number of printing andconverting stations for application and drying of pigmented inks,coatings, and adhesives, and for converting processes such as unwinding,turning, die cutting, joining and re-winding. Multi-unit presses of thisclass are preferred for producing labels of the present invention andare known in the art to include a variety of modular, interchangeableunits. Specifically, any of the exemplary units 340-382 may be arrangedin any desired order and, of course, units may also be added or removedfrom installation 300 as desired or required by process variations. Asunderstood by those skilled in the printing arts, multi-unit press 310may be any suitable narrow- or wide-web platform press such as aflexographic, letterpress, gravure, screen, or offset press. Suchpresses are commercially available from, for example, ComcoInternational of Milford, Ohio, or Mark Andy Inc. of St. Louis, Mo. Itwill also be appreciated that as used herein throughout and in thedrawings, the terms “printing”, “graphics” and “coatings” include, butare not limited to, various printing media, adhesives, hot melts,varnishes, inks, release coatings, hot and cold foil stamping processes,etc.

With continued reference to FIG. 3, and as an example of construction ofthree-ply labels 10 as depicted in FIG. 1, top web 320U (correspondingto top ply 18 in FIG. 1) is supplied in a conventional roll form topress 310 at unwind unit 330 c, and in a lengthwise machine direction Mthereto. Intermediate web 320I (middle ply 30 in FIG. 1) and base web320B (base ply 12 in FIG. 1) are also preferably supplied inconventional roll forms to press 310 at unwind units 330 b and 330 a,respectively, also in lengthwise machine direction M. Webs 320U, 320I,and 320B are any suitable in-line web-like materials. As used herein,“web-like materials” denotes any suitable label ply material orcombination hereof, including but not limited to paper, film,polypropylene, polyethylene, polyester, polyvinylchloride, polystyrene,foil, and ethylene vinyl acetate, whether clear or opaque. Further, baseweb 320B may comprise a conventional so-called “pressure sensitivelaminate”.

Unwind units 330 a-c pass webs 320B, I, and U, respectively, to firstprinting units 340 a-c, where selected graphics may be printed on thewebs. Webs 320I and 320U then advance to optional web turning units 350b-c, respectively, where the webs may be turned for printing on theirreverse sides if desired by way of any suitable turn-bar or liketechnique as known in the art. If so optionally turned, webs 320I and320U then advance to second printing units 360 b-c, respectively, whereselected graphics may be printed on the reverse sides thereof.

After passing from first printing unit 340 a, web 320B advances to unit350 a for selective application of a release coating as at 26 in FIG. 1,and to unit 360 a for selective application of a permanent hingeadhesive coating as at 24 in FIG. 1. With release and adhesive coatingsapplied in a desired pattern, web 320B then passes on to unit 362 wherea pressure-sensitive adhesive-based release-reseal system is created byadding PSA at 28.

An important advance in the process of the invention involves thecontinuous on-web sizing of each middle or intermediate ply as web 320Iis continually processed concurrently with web 320B. From secondprinting unit 360 b, web 320I advances to a first die cutting unit 364where web 320I is selectively die cut on the web to provide a dimensionfor middle ply 30 that, as indicated, is different from a final overallor outer label dimension, web 320I remaining intact. Criticalprint-to-print and cut-to-cut registration is maintained between theconcurrently processed webs, and ultimately the finished product plies,because web 320I is allowed to remain intact after die cutting at unit364, the cut ply being held intact by uncut tabs such as those shown at35 in FIGS. 4a-b. The die cut area in the ply is denoted as “D” in FIGS.4a-b.

Webs 320B and 3201 then advance to first nip roller web joining unit 370where they are adhesively joined or “married” in aligned print-to-printregistration to form a combined web 320C. Such marrying of webs 320B andI may be accomplished by, for example, any suitable nip roller or webjoining technique as known in the art. Combined web 320C then passes towaste matrix removal unit 372 where a waste matrix from an unusedportion of web 320I, resulting from operation of first die cutting unit364, is removed in any well-known waste matrix removal or “stripping”operation. The stripping operation, as will be appreciated by thoseskilled in the art, results in creation of individual, discrete labelelements on the combined web 320C.

After the stripping process, combined web 320C carrying individual,discrete label elements passes to unit 374, where hinge adhesive and/orgraphics are applied to the combined web 320C in a portion remote fromthe release-reseal system. Web 320C then advances to second nip rollerweb joining unit 380, where web 320U is also introduced inprint-to-print registration with its counterpart web 320C to form anoverall label structure web 320L. Label structure web 320L is thenpassed to second die cutting unit 382, where the web is die cut (toproduce final label dimensions) and a final waste matrix is strippedaway. In this manner, individual finished labels are provided in labelstructure web 320L having desired final dimensions.

Label structure web 320L then passes to final re-wind unit 390 forre-winding into a finished press roll 399P carrying individual labels(as shown, for example, in FIG. 6). Alternatively, web 320L may be“sheeted” for use with various other container decorating methods, as isknown in the art.

As indicated above, it will be appreciated and understood that the firstdie cutting step and reliable operation of first die cutting unit 364are critical, to accurate creation in web 320I of a middle ply 30 (FIGS.1-2) having dimensions different than plies 12 and 18 as mentionedabove. This die cutting operation at unit 364, of course, assures thatply 30 resulting from web 320I does not have die cut dimensionsequivalent to those overall final dimensions provided to individuallabels in label structure web 320L. Further, it is to be particularlyappreciated that the technique of leaving web 320I intact immediatelyafter the first die cutting operation creates a selected waste matrix inthe manufacturing method of the present invention that advantageouslyenables a completely in-line, single pass process to succeed. It is tobe noted that in-line processes must maintain print-to-print andcut-to-cut registration, which is imperative when providing generallylarge amounts of information on limited surface areas.

Although three webs are depicted in FIG. 3 (320U, 320I, and 320B)various plow folding and slitting techniques could allow a lesser numberof webs to be used in this process; commensurately, however, finishedproduct yields would be decreased. Additionally, several “pages” ofinformation could effectively be provided in, for example, web 320I byway of one or more plow folding operations (not illustrated) before diecutting at unit 364. Further, a portion of web 320I could be removed by“slugging” or another suitable technique, prior to marrying the webs(370).

Of course, the process described herein could employ and join additionalwebs providing additional label plies in the manner of processingdescribed in the embodiments described herein as will be evident tothose skilled in the art.

Turning, now, to FIG. 5, a technique for manufacturing the labels of thepresent invention using a single web is schematically depicted. Therein,an exemplary in-line single web press manufacturing installation 500includes multi-unit modular in-line printing and converting press 510.

Multi-unit press 510 of installation 500 includes (i) unwind unit 530,(ii) multi-graphic printing unit 540, (iii) combination graphic,varnish, and web turning unit 550, (iv) hinge and release-reseal systemunit 560, (v) die cutting unit 570, (vi) combination slitting and/orplow folding, and web turning unit 575, (vii) nip roller web joiningunit 580, (viii) final die cutting and waste matrix removal unit 585,and (ix) final re-wind unit 590, as will now each be further described.

It is to be understood that press 510 is also selectively capable ofproviding a variable number of stations as described relative to thepress of FIG. 3.

In an example of construction of three-ply labels 10 in this single webprocess, a single web 520 is supplied in a conventional roll form topress 510 at unwind unit 530, and in a lengthwise machine direction Mthereto. Of course, web 520 may comprise any suitable in-line web-likematerials, as aforedescribed.

Unwind unit 530 passes web 520 to multi-graphic printing unit 540 whereselected multiple graphics are printed on the web. Web 520 then advancesto combination graphic, varnish, and web turning unit 550, where eachside of the web may be selectively coated with graphics and varnish. Web520 then advances to hinge and release-reseal system unit 560, where, asaforedescribed, a release-reseal system is provided.

After passing from unit 560, web 520 advances to die cutting unit 570where the web is die cut to create a “window” in the web. The “window”represents that portion of the area of the intermediate ply or plieswhich needs to be removed in order to reduce them to the desired sizefor inclusion inside the label 10. It is to be understood that,alternatively or in combination, the aforedescribed selective diecutting and waste matrix removal method may be utilized. Web 520 is thenpassed to slitting and/or plow folding unit 575, where a slitting and/orplow folding operation is performed. It is to be appreciated that thesedie cutting and slitting and/or plow folding operations create multipleplies from a single web. Web 520 having the multiple plies then advancesto nip roller web joining unit 580, where it is compressed, and foldstherein are creased.

Web 520 then passes to final die cutting and waste matrix removal unit585 where a waste matrix resulting from the final die cutting isremoved.

After the process of stripping away the waste matrix, web 520 becomes anarray of individual labels as aforedescribed.

It will be appreciated and understood that web 520 might have aconventional pressure-sensitive laminate construction. Likewise, web 520could be in a form of a film material web whereupon a pressure-sensitivetransfer adhesive with a liner (not illustrated) is introduced justbefore the web reaches the nip roller (unit 580) thereby creating apressure-sensitive laminate label construction.

This invention has been described herein in considerable detail in orderto comply with the patent statutes and to provide those skilled in theart with the information needed to apply the novel principles and toconstruct and use such specialized components as are required. However,it is to be understood that the invention can be carried out byspecifically different equipment and devices, and that variousmodifications, both as to the equipment and operating procedures, aswell as materials, can be accomplished without departing from the scopeof the invention itself.

For example, it will be appreciated that any of the aforedescribedgraphics, coatings, materials, and release-reseal systems may beselectively provided in any suitable combination on labels constructedaccording to the present invention, for a particular desired use. Thus,in FIGS. 1-2, the relative positions of coatings 26 and 28 could beinterchanged by way of corresponding modifications to, for example,press 310 in FIG. 3.

It is also to be understood in general that any suitable alternativesmay be employed to provide the process for manufacturing multi-plylabels of the present invention.

Lastly, the choice, of course, of compositions, sizes, and strengths ofvarious aforementioned components of the present invention are all amatter of design choice depending upon intended uses thereof.

What is claimed is:
 1. A continuous single pass process for creatingmulti-ply selectively resealable booklet labels wherein base plies and,selectively, top plies flank one or more dimensionally shorterintermediate plies comprising steps of: (a) supplying at least a firstcontinuous single ply intermediate web from a source thereof andselectively applying graphics thereto in accordance with a series ofintermediate label ply shapes; (b) selectively and partially cuttingsaid single ply intermediate web, thereby defining and pre-sizing, butnot totally severing, said series of intermediate label ply shapesproducing a single ply pre-cut intermediate web of pre-sizedintermediate label ply shapes while still maintaining web integrity; (c)supplying a continuous base web from a source thereof and selectivelyapplying graphics thereto in accordance with a series of base label plyshapes; (d) thereafter continuously adhesively joining said pre-cutcontinuous intermediate web with said continuous base web, said baselabel ply shapes being in lateral aligned relation to said intermediatelabel ply shapes, as pre-sized, and forming hinges therebetween along analigned side, thereby also forming a first combined web; and (e)thereafter removing a waste matrix consisting of that part of saidintermediate web surrounding said pre-sized intermediate label plyshapes by stripping said waste matrix from said first combined web.
 2. Aprocess as in claim 1 wherein said base web includes a carrier ply.
 3. Aprocess as in claim 2 wherein said intermediate label ply shapes aredimensionally smaller than said base label ply shapes.
 4. A process asin claim 3 wherein said intermediate label ply shapes are dimensionallyshorter than said base label ply shapes in a direction perpendicular tosaid hinges.
 5. A process as in claim 1 wherein said intermediate labelply shapes are dimensionally smaller than said base label ply shapes. 6.A process as in claim 5 wherein said intermediate label ply shapes aredimensionally shorter than said base label ply shapes in a directionperpendicular to said hinges.
 7. A process as in claim 5 wherein saidpartial cutting of step (b) completely severs said series ofintermediate label ply shapes except for a plurality of minor tabs alongopposite sides thereof.
 8. A process as in claim 6 wherein said partialcutting of step (b) completely severs said series of intermediate labelply shapes except for a plurality of minor tabs along opposite sidesthereof.
 9. A process as in claim 1 including the further step ofcutting said first combined web to produce a desired final overallindividual label dimension.
 10. A process as in claim 1 including thefurther steps of: (f) supplying a single ply top web from a continuoussource thereof and selectively applying graphics thereto in accordancewith a series of top label ply shapes; (g) continuously adhesivelyjoining said first combined web with said top web having said top labelply shapes in aligned relation to said intermediate label ply shapes ofsaid first combined web and selectively forming hinges therebetweenthereby also forming a second combined web carrying combined labelstructures; and (h) cutting said combined label structures to produce adesired final overall individual label dimension.
 11. A process as inclaim 10 wherein said base web includes a carrier ply.
 12. A process asin claim 11 wherein said intermediate label ply shapes are dimensionallysmaller than said base label ply shapes and said top label ply shapes.13. A process as in claim 12 wherein said intermediate label ply shapesare dimensionally shorter than said base label ply shapes and said toplabel ply shapes in a direction perpendicular to said hinges.
 14. Aprocess as in claim 12 wherein said partial cutting of step (b)completely severs said series of intermediate label ply shapes exceptfor a plurality of minor tabs along opposite sides thereof.
 15. Aprocess as in claim 13 wherein said partial cutting of step (b)completely severs said series of intermediate label ply shapes exceptfor a plurality of minor tabs along opposite sides thereof.
 16. Aprocess as in claim 13 wherein said intermediate label ply shapes aredimensionally smaller than said base label ply shapes and said top labelply shapes.
 17. A process as in claim 16 wherein said intermediate labelply shapes are dimensionally shorter than said base label ply shapes andsaid top label ply shapes in a direction perpendicular to said hinges.18. A process as in claim 10 further comprising a step of removing afinal waste matrix comprising material of said second combined websurrounding said final overall individual label dimension.
 19. A processas in claim 10 wherein said hinges are adhesively joined using apermanent adhesive.
 20. A process as in claim 19 wherein the permanentadhesive of said hinges is selected from the group consisting of hotmelt adhesives, solvent-based adhesives, water-based adhesives,UV-curable and EB-curable adhesives.
 21. A process as in claim 10comprising the further step of providing a release-reseal system,releasably, resealably joining an upper side of said base ply and anunder side of said top ply along an edge opposite said hinges in saidcombined label structure.
 22. A process as in claim 21 wherein saidrelease-reseal system comprises a layer of pressure sensitive adhesiveand a layer of release coating substantially aligned therewith.
 23. Aprocess as in claim 10 wherein said intermediate ply and said top plyare commonly hinged to said base ply, in a shared hinge fashion.
 24. Aprocess as in claim 23 further comprising steps of adding at least oneadditional intermediate ply, consecutively hinged to said intermediateply.
 25. A process as in claim 10 wherein said intermediate ply ishinged to said base ply and said top ply is consecutively hinged to saidintermediate ply in adhesive sandwich fashion.
 26. A process as in claim25 further comprising steps of adding at least one additionalintermediate ply, consecutively hinged between said top ply and saidbase ply.
 27. A process as in claim 1 wherein said hinges are adhesivelyjoined using a permanent adhesive.
 28. A process as in claim 27 whereinthe permanent adhesive of said hinges is selected from the groupconsisting of hot melt adhesives, solvent-based adhesives, water-basedadhesives, and UV-curable and EB-curable adhesives.
 29. A process as inclaim 1 wherein said partial cutting of step (b) completely severs saidseries of intermediate label ply shapes except for a plurality of minortabs along opposite sides thereof.
 30. A continuous single pass processfor creating multi-ply selectively resealable booklet labels whereinbase plies and, selectively, top plies flank one or more dimensionallyshorter intermediate plies comprising steps of: (a) supplying at least afirst continuous single ply intermediate web from a source thereof andselectively applying graphics thereto in accordance with a series ofintermediate label ply shapes; (b) selectively and partially cuttingsaid single ply intermediate web, leaving a plurality of minor tabsretaining said intermediate label ply shapes, thereby defining andpre-sizing, but not totally severing, said series of intermediate labelply shapes producing a single ply pre-cut intermediate web of pre-sizedintermediate label ply shapes while still maintaining web integrity; (c)supplying a continuous base web from a source thereof and selectivelyapplying graphics thereto in accordance with a series of base label plyshapes; (d) thereafter continuously adhesively joining said pre-cutcontinuous intermediate web with said continuous base web, said baselabel ply shapes being in lateral aligned relation to said intermediatelabel ply shapes, as pre-sized, and forming hinges therebetween along analigned side, thereby also forming a first combined web; and (e)thereafter removing a waste matrix consisting of that part of saidintermediate web surrounding said pre-sized intermediate label plyshapes, by stripping said waste matrix from said first combined webthereby at the same time also severing said minor tabs.
 31. A process asin claim 30 including the further steps of: (f) supplying a single plytop web from a continuous source thereof and selectively applyinggraphics thereto in accordance with a series of top label ply shapes;(g) continuously adhesively joining said first combined web with saidtop web having said top label ply shapes in aligned relation to saidintermediate label ply shapes of said first combined web and selectivelyforming hinges therebetween thereby also forming a second combined webcarrying combined label structures; and (h) cutting said combined labelstructures to produce a desired final overall individual labeldimension.
 32. A process as in claim 31 wherein said intermediate labelply shapes are dimensionally smaller than said base label ply shapes andsaid top label ply shapes.
 33. A process as in claim 32 wherein saidintermediate label ply shapes are dimensionally shorter than said baselabel ply shapes and said top label ply shapes in a directionperpendicular to said hinges.